Composite insulated building block and wall structure



A. PERRETON Sept. 7, 1965 COMPOSITE INSULATED BUILDING BLOCK AND WALLSTRUCTURE 3 Sheets-Sheet 1 Filed Oct. 12, 1962 INVENTOR Xewoza ee/e570ATTORNEY A. PERRETON Sept. 7, 1965 COMPOSITE INSULATED BUILDING BLOCKAND WALL STRUCTURE 25 Sheets-Sheet 2 Filed Oct. 12, 1962 INVENTOR494/040 aeesra/v BY W- ATTORNEY A. PERRETON Sept. 7, 1965 COMPOSITEINSULATED BUILDING BLOCK AND WALL STRUCTURE 5 Sheets-Sheet 5 Filed Oct.12, 1962 INV EN TOR 149N040 paees Tau ATTORNEY United States Patent3,204,381 COMPOSHE INSULATED BUILDING BLOCK AND WALL STRUCTURE ArnoldPerreton, Concord, N.H., assignor to Formbloc, Inc., Concord, N.H., acorporation of Massachusetts Filed Get. 12, 1962, Ser. No. 230,196 9Claims. (Cl. 52-309) This invention relates to building structures andmore particularly to a composite insulated building block and wallstructure in which the composite block materially facilitates theconstruction of a wall to provide uniform horizontal and vertical mortarjoints therein and also serves to provide a wall having high thermalinsulation and moisture barrier characteristics.

Numerous types of insulated building blocks have heretofore beenproposed and utilized, but many of these merely provide air spaces forinsulation purposes and where such air spaces are made large enough toaccomplish an insulating function, the load-carrying characteristics ofthe block have been materially reduced and furthermore, these prior artblocks do not provide elfective moisture barriers or cooperate in amanner to automatically assure uniform horizontal and vertical mortarjoints, thereby requiring a high degree of skill on the part of themason laying the wall.

It is accordingly an object of the invention to provide a compositeinsulated building block, including a block of concrete or similarcementitious material having maximum load carrying characteristics andproviding a space for receiving one or more blocks of lightweightinsulating material which serves to provide a barrier to the transverseflow of heat or moisture through the block.

A further object of the invention is the provision of a compositeinsulated building block, including a block of concrete or othercementitious material and providing space within the block for receivinga block of lightweight insulating material and in which the block ofinsulating material may be inserted in the building block prior tolaying the same in a wall or other structure or in which the insulatingblock may be inserted in the building blocks of each course as the wallis laid up.

A still further object of the invention is the provision of a compo-siteinsulated building block, including -a block of concrete or othercementitious material and providing a space within the building blockfor receiving a block of lightweight insulating material and in whichsuch block of insulating material may be provided as a unit for eachbuilding block or may be provided in a strip of any desired length to bereceived in a plurality of building blocks.

Another object of the invention is the provision of a compositeinsulated building block, including a building block of concrete orother cementitious material having outer sidewalls and an intermediatewall, together with webs connecting one sidewall to the intermediatewall and other webs disposed in staggered relationship connecting theother sidewall to the intermediate Wall, all of the webs havingdownwardly extending notches therein and blocks of lightweightinsulating material received between the sidewalls and the intermediateWall in the notches in the webs and serving to provide a continuous heatand moisture barrier within the building block and opposite all of thewebs.

A further object of the invention is the provision of a compositeinsulated building block in which the building block is provided withsidewalls and an intermediate wall connected by webs disposed instaggered relationship, there being blocks of insulating materialdisposed between the sidewalls and the intermediate wall, suchinsulating blocks projecting above the upper edge of the building blockand having notches therein to engage the lower edges of the webs of ablock in the next course of blocks to accurately locate and space theblocks to provide uniform horizontal and vertical mortar joints, atleast one of the insulating blocks having upwardly extending notchestherein for engaging the webs of adjacent blocks in the same course tolink the same together and also to permit overlapping of insulatingblocks in the building blocks of the same course.

A still further object of the invention is the provision of a compositeinsulated building block, including a building block of concrete orother cementitious material and a block of lightweight insulatingmaterial received within the confines of the building block, suchinsulating block being of a size to engage portions of adjacent buildingblocks and insulating blocks to accurately locate and space the same,thereby providing uniform horizontal and vertical mortar joints.

Another object of the invention is the provision of a compositeinsulated building block, including a building block of concrete orother cementitious material and a lightweight insulating block receivedwithin the confines of the building block and with one side of theinsulating block offset longitudinally and vertically with respect tothe opposite side of the insulating block to provide a shiplap structurewhich serves to interlock and cooperate with the insulating block in theadjacent building block of a wall.

A further object of the invention is the provision of a compositeinsulated building block having sidewalls and connecting webs and inwhich the Webs are so arranged as to be disposed one under the otherwhen the block is utilized in building a wall thereby providingadditional load carrying characteristics.

A still further object of the invention is the provision of a compositeinsulated building block, including a building block of concrete orother cementitious material and a block of insulating material receivedwithin the confines of the building block, such insulating blockcomprising rigid foam of polystyrene or other suitable material, suchfoam consisting of non-connected cells thereby providing both a thermalinsulation and a moisture barrier.

Another object of the invention is the provision of a compositeinsulated building block including a building block of concrete or othercementitious material and a block of lightweight insulating materialreceived between the sidewalls of the building block with air spacesbeing provided between the insulating block and the inner surfaces ofthe sidewalls of the building block to provide additional thermalinsulation.

A further object of the invention is the provision of a wall constructedby utilizing the composite insulated building blocks of this invention.

Further objects and advantages of the invention will be apparent fromthe following description taken in conjunction with the accompanyingdrawings wherein:

FIG. 1 is a view in perspective showing a building block constructed inaccordance with one embodiment of the invention; I

FIG. 2 is a view in perspective showing one of the insulating blocksutilized with the building block of FIG. 1;

FIG. 3 is a view in perspective showing the building block of FIG. 1with two of the insulating blocks of FIG. 2 incorporated therein in fulllines and showing in dotted lines the position of adjacent insulatingblocks;

FIG. 4 is a top plan view of a wall constructed with the building blockof FIG. 1 and the insulating block .of FIG. 2 and showing the relativepositions of the building blocks and insulating blocks in the wall;

FIG. 5 is a side elevational view of the wall shown in FIG. 4 andshowing the relationship of the cross webs of the building blocks ineach course, as well as the uniform horizontal and vertical mortarjoints;

FIG. 6 is a sectional view taken substantially on the line 6-6 of FIG.

FIG. 7 is a sectional view taken substantially on the line 7-7 of FIG.6;

FIG. 8 is a view in perspective showing a building block constructed inaccordance with the preferred form of the invention;

FIG. 9 is a view in perspective showing an insulating block for use withthe building block of FIG. 8;

FIG. 10 is a view in perspective showing the building block of FIG.8with the insulating block of FIG. 9 incorporated therewith;

FIG. 11 is a top plan view of a wall constructed with the building blockof FIG. 8 and the insulating block of FIG. 9;

FIG. 12 is a front elevational view of the wall shown in FIG. 11;

FIG. 13 is a sectional view taken substantially on the line 1313 of FIG.12.

FIG. 14 is a sectional view taken substantially on the line 1414 of FIG.12;

FIG. 15 is a sectional view taken substantially on the line 1515 of FIG.13;

'FIG. 16 is a view in perspective showing an insulating blockconstructed in accordance with a still further modified form of theinvention;

FIG. 17 is a top plan view of a wall constructed with the building blockof FIG. 8 andthe insulating block of FIG. 16;

FIG. 18 is a front elevational view of the wall of FIG. 17;

FIG. 19 is a sectional view taken substantially on the line 19--19 ofFIG. 18.

With continued reference to the drawings, there is shown in FIG. 1 abuilding block constructed in accordance with one embodimentof theinvention, and such block may be composed of concrete or other suitablecementitious material and may include spaced parallel generallyrectangular sidewalls .10 and 11 and an intermediate wall 12. Verticalend webs 13 and 14, as well as an intermediate web 15 connect thesidewall 10 to the intermediate wall 12, and it is to be noted that thethicknesses of the end webs 13 and 14 are approximately onehalf thethickness of the intermediate web 15. A pair of spaced vertical webs 16and 17 connect the sidewall 11 with the intermediate wall 12, and it isto be noted that the webs 16 and 17 are staggered with respect to thewebs 13, 14 and 15 or, in other words, the web 16 is disposed in a-planebetween the intermediate web 15 and the end web 13 and the web 17 isdisposed in a plane between the web 15 and the end web 14.

The sidewalls 10 and 11 and the intermediate wall 12 connected to thesidewalls by the cross webs mentioned above provide a unitary structureand the webs 13, 14 and 15 are provided with notches 18, 19 and 20respectively extending downwardly to a point intermediate the heightthereof and it is to be noted that the outer side edges 21, 22 and 23 ofthe notches 18, 19 and 20 are spaced in- .wardly from the inner surface24 of the sidewall/10. In a similar manner, the webs 16 and 17 areprovided with notches 25 and 26 extending downwardly therein and theouter side edges 27 and 28 are spaced-inwardly from the inner surface 29of the sidewall 11.

With particular reference to FIG. 2, there is shown an insulating block30 for use with the building block 31 of FIG. 1 and the insulating block30 may be formed of lightweight rigid foam material, such as polystyreneand may be provided with spaced parallel notches 32 and 33 extendingupwardly from the lower edge 34 of the blocks 30 and it is to be notedthat the heights of the notches 32 and 33 are less than the height ofthe lower portions of the webs of the building blocks 31 for a purposeto be later described. The insulating block 30 is also provided withspaced downwardly extending notches 35 and 36 in the upper edge thereofand such notches-are in alignment with the upwardly extending notches 32and 33.

The thickness of the insulating block 30 is approximately equal to thedistance between the inner edges of the notches in the webs of thebuilding blocks 31 and the outer surfaces of the intermediate wall 12and as shown in FIG. 3, one insulating block 30 is disposed between thesidewall 10 and the intermediate wall 12 with the lower portions of thewebs 15 and 14 of the building block 31 received in the notches 32 and33 respectively of the insulating block 30 which results in one end ofthe insulating block 30 projecting from the end of the building blocks31 and the opposite end disposed within the building blocks 31. A secondinsulating block 30 is disposed between the sidewall 11 and theintermediate wall 12 of the building block 31 with the lower portions ofthe webs 16 and 17 received in the notches 32 and 33 of the buildingblocks 30 thereby disposing the second insulating block 31)substantially within the confines of the building block 31. As clearlyshown in FIG. 3, the upper edges of the two insulating blocks 30positioned in the building block 31 project above the upper edge thereofand as clearly shown in FIG. 6, the lower edges of the insulating blocks30 are disposed above the lower edges of the building block 31.

With the above described arrangement of the insulating blocks 30 in thebuilding block 31, it will be seen that a portion of at least one of theinsulating blocks 30 will be disposed opposite the connecting part ofeach web and, therefore, there is provided a continuous barrier to thetransverse flow of heat or moisture through the buildling block 31.

With particular reference to FIGS. 4 to 7, there is shown a wallconstruct-ed with the building block 31 of FIG. 1 and the insulatingblock 30 of FIG. 2, such wall being laid in a broken joint pattern andit will be seen that the lower surfaces 37 of the downwardly extendingnotches 35 and 36 of the insulating blocks 30 are disposed above theupper edges 38 of the sidewalls 10 and 11 of the building block 31 adistance equal to the width of a mortar joint and as clearly shown inthese figures, the lower portions of the webs of the building blocks 31in the upper course 39 are received in the notches 35 and 36 of theinsulating blocks 30 in the next lower course 40 which serves toaccurately space the blocks vertically and also to accurately space theblocks horizontally, thereby providing uniform horizontal mortar joints41 and uniform vertical mortar joints 42. As clearly shown in FIG. 4,the insulating blocks 30 in the building block 31 abut each other inend-to-end relationship to provide a continuous heat insulating andmoisture barrier in the Wall.

When constructing the wall, the second tier of blocks may, if desired,be laid in place prior to positioning the insulating blocks therein,since the engagement of the lower portions of the webs in the secondtier of blocks with the downwardly extending notches in the insulatingblocks of the lower tier serve to accurately locate the blocks of theupper tier or course and thereafter, the insulating blocks may be placedin the building blocks of the upper course and such insulating blocks 30may be formed as single units for each building block as shown, or maybe constructed in continuous lengths to be inserted in any desired orconvenient number of building blocks 31. In this manner, a wall may berapidly and efiiciently constructed without requiringv great skill toprovide uniform mortar joints and, furthermore, a continuous sheetinsulating and moisture barrier is provided in the wall by theinsulating blocks and additional heat insulation is provided by the airspaces between the surfaces of the insulating blocks and the innersurfaces of the walls 10 and 11 of the building block 31 between thewebs as clearly shown in FIG. 4.

With particular reference to FIG. 8, there is shown the preferred formof building block 43 which may be constructed of the same material asthe building block described above and such building block 43 may Wellcomprise spaced parallel rectangular sidewalls 44 and 45 connected byspaced parallel vertical webs 46 and 47 to provide a unitary structure.Webs 46 and 47 are provided with downwardly extending notches 48 and 49terminating at a point intermediate the height thereof and the sideedges 50 and 51 of the notches 48 and 49 are spaced inwardly from theinner surfaces 52 and 53 of the sidewalls 44 and 45.

With particular reference to FIG. 9, there is shown an insulating block54 formed of rigid foam material, such block being of a thickness to betightly received in the notches 48 and 43 of the building block 43 asclearly shown in FIG. 10 and the insulating block 54 is provided withspaced parallel upwardly extending notches 55 and 56 for receiving thelower portions of the webs 46 and 47 of the building block 43. It is tobe noted that the length and height of the insulating block 54 issomewhat greater than the length and height of the building block 43, byreason of which, when positioned in the building block 43 as shown inFIG. 10', one end of the insulating block 54 will project beyond theadjacent end of the sidewalls 44 and 45 of the building block 43 and theupper edge of the insulating block 54 will project above the upper edgeof the building block 43.

With particular reference to FIGS. 11 to 15, there is shown a wallconstructed by utilizing the building blocks 43 and the insulatingblocks 44 and, as clearly shown in FIG. 14, the projecting upper edge ofthe insulating block 54 of the lower course 57 engages the lower edgesof the webs 46 and 47 of the building block 43 in the second course 58to accurately space such blocks vertically thereby providing uniformhorizontal mortar joints 59. As clearly shown in FIG. 11, the projectingend of the insulating block 54 of one building block 43 engages theadjacent end of the insulating block 54 of the adjacent building block43 to accurately space the building blocks 43 horizontally therebyproviding uniform vertical mortar joints 60. It is also to be noted asclearly shown n FIG. 12, that the webs 46 and 47 of each course are inalignment with the webs of the next upper course thereby providingmaximum weight carrying capacity. The insulating characteristics of theinsulating block 54, as well as the moisture barrier characteristicsthereof in conjunction with the air spaces between the insulating block54 and the inner surfaces 52 and 53 of the sidewalls 44 and 45 of thebuilding block 43 serve to provide adequate heat insulating and moisturebarrier characteristics in a wall constructed with these blocks.

With particular reference to FIG. 16, there is shown a modified form ofinsulating block 61 for use with the building block 43 of the FIG. 10and as before, the insulating block 61 is formed of suitable rigid foammaterlal and the block 61 is provided with spaced parallel upwardlyextending notches 62 and 63 and as clearly shown in FIG. 16, one side 64is offset, both longitudinally and vertically, from the opposite side 65to provide an upstanding rib 66 on one side of the upper edge of theinsulating block 61 and a depending rib 67 on the opposite side of thelower edge of the block 61. Also a flange 68 projects outwardly from oneend of the block 61 in alignment with the rib 66 and a second flange 69projects outwardly from the opposite end of the block 61 in alignmentwith the rib 67. These flanges 63 and 69, instead of being planar ontheir ends, could be provided with a tongue and groove connection, ifdesired. The same is true of the upper and lower ribs. The upstandingrib 66 is provided with spaced parallel downwardly extending notches 70and 71 terminating at the upper edge 72 of the block 61 and being inalignment with the upwardly extending notches 62 and 63. The insulatingblock 61 is positioned the lower portions of the webs 46 and 47 arereceived in the upwardly extending notches 62 and 63 of the insulatingblock 61 and, as clearly shown in FIGS. 17 and 19, one end of theinsulating block 61 projects beyond the adjacent end of the buildingblock 43 while the upper edge and rib 66 of the insulating block 61projects above the upper edge of the building block 43 and the loweredge of the depending rib 67 of the insulating block 61 is flush withthe lower edge of the building block 43.

With particular reference to FIGS. 17 to 19 there is shown a wallconstructed by utilizing the building block 43 of FIG. 10 and theinsulating block 61 of FIG. 16 and, as clearly shown, the upwardlyextending rib 66 and depending rib 67 of adjacent lower and uppercourses 73 and 74 interlock to provide a ship-lap construction and, in asimilar manner, the adjacent end flanges 68 and 69 also interlock toprovide a ship-lap construction. Furthermore, the engagement of the endsof the insulating blocks 61 in adjacent building blocks 43, as well asthe engagement of the lower edges of the ribs 46 and 47 in the notches70 and 71 and with the upper surface 72 of the insulating blocks 61serves to provide accurate spacing between the building blocks 43,thereby providing uniform horizontal and vertical mortar joints, Also inthis form of the invention, the webs 46 and 47 of the building blocks 43are positioned in vertical alignment to increase the load-carryingcapacity and the insulating block 61, together with the air spacesprovided between such blocks and the inner wall surfaces of the buildingblocks 43 serve to provide adequate heat insulation, as well as abarrier against the passage of moisture transversely through thebuilding blocks 43.

It will be seen that by the above described invention there has beenprovided a highly effective composite insulated building block which maybe conveniently utilized for constructing Walls or other structures andvarious forms of building blocks and insulating blocks are provided bythe invention by means of which maximum insulating and moisture-proofcharacteristics, aswell as load-carrying characteristics are secured andsince the insulating blocks may be made of extremely lightweight rigidfoam material, little Weight is added to the wall and in fact, thebuilding blocks may be made to minimum sizes for accommodating therequired load, since the entire heat insulating and moisture-proofcharacteristics are provided by the insulating blocks utilized inconjunction with the building blocks. The particular structure of boththe building blocks and insulating blocks of this invention areparticularly well adapted to mass production and also serve tomaterially facilitate the construction of a wall or other structure bylabor utilizing a minimum of skill in such matters.

-It will be obvious to those skilled in the art that various changes maybe made in the invention without departing from the spirit and scopethereof and therefore the invention is not limited by that which isshown in the drawings and described in the specification, but only asindicated in the appended claims.

What is claimed is:

'1. A composite insulated building block comprising spaced parallelrectangular sidewalls and an intermediate wall, vertical end webs and anintermediate web connecting one sidewall and said intermediate wall, thethickness of each end web being approximately one-half the thickness ofsaid intermediate web, a pair of spaced vertical webs connecting theother sidewall and said intermediate wa-ll, one of said pair beingdisposed in a plane between said intermediate web and one end web andthe other of said pair being disposed in a plane between saidintermediate web and the other end web, said walls and webs :being ofcementitious material and providing a unitary structure, each web havinga notch extending downwardly tfrom the upper edge to a pointintermediate the height of said web, the outer side edges of the notchesin said end and intermediate webs being spaced inwardly from the innersurface of said one sidewall, the outer side edges of the notches insaid pair of webs being spaced inwardly from the inner surface of saidother sidewall and a pair of separate generally rectangular blocks ofinsulating rigid foam material, each insulating block having two spacedparallel notches extending upwardly from the lower edge, the height ofsaid last named notches being less than the height of said webs belowthe notches therein and spaced downwardly extending notches in the upperedge of said insulating block in alignment with said upwardly extendingnotches, one of said insulating block-s being received between said onesidewall and said intermediate wall with one upwardly extending notchreceiving the lower portion of said intermediate web and the otherupwardly extending notch receiving the lower portion of one end web, theother insulating block being received between said other sidewall andsaid intermediate wall with the upwardly extending notches receiving thelower portions of said pair of webs, the lower edges of said insulatingblocks being spaced above the lower edges of said walls and the upperedges projecting above the upper edges of said walls 'by the width of amortar joint downwardly extending notches being spaced above the upperedges of said walls by the width of a motar joint to provide .acomposite building block with insulation provided by said insulatingblocks and the air spaces between the outer sides of said insulatingblocks and the inner surfaces of said sidewalls.

2. A composite insulated building block comprising spaced parallelrectangular sidewalls and an intermediate wall, vertical end webs and anintermediate web connecting one sidewall and said intermediate wall, apair of spaced vertical webs connecting the other sidewall and saidintermediate wall, one of said pair being disposed in a plane betweensaid intermediate web and one end web and the other of said pair beingdisposed in a plane between said intermediate web and the other end web,said walls and webs being of cementitious material and providing aunitary structure, each web having a notch extending downwardly from theupper edge to a point intermediate the height of said web, the outerside edges of the notches in said end and intermediate web being spacedinwardly from the inner surface of said one sidewall, the other sideedges of the notches in said pair of webs being spaced inwardly from theinner surface of said other sidewall and a pair of separate generallyrectangular blocks of insulating rigid foam material, each insulatingblock having two spaced parallel notches extending upwardly from thelower edge, the height of said last named notches being less than theheight of said Webs below the notches therein and spaced downwardlyextending notches in the upper edge of said insulating block inalignment with said upwardly extending notches, one of said insulatingblocks being received between said one sidewall and said intermediatewall with one upwardly extending notch receiving the lower portion ofsaid intermediate web and the other upwardly extending notch receivedthe lower portion of one end web, the other insulating block beingreceived between said other sidewall and said intermediate wall with theupwardly extending notches receiving the lower portions of said pair ofwebs, the lower edges of said insulating blocks being spaced above thelower edges of said walls and the upper edges projecting above the upperedges of said walls with the lower surfaces of said downwardly extendingnotches being spaced abovethe upper edges of said walls by the width ofa mortar joint to provide a composite building block with insulationprovided by said insulating blocks and by the air spaces between theouter sides of said insulating blocks and the inner surfaces of saidsidewalls.

3. A composite insulated building block comprising spaced parallelrectangular sidewalls and an intermediate wall, vertical end webs and anintermediate web connecting one sidewall and said intermediate wall, apair of spaced vertical webs connecting the other sidewall and saidintermediate wall, one of said pair being disposed in a plane betweensaid intermediate web and one end web and the other of saidpair beingdisposed in a plane between said intermediate web and the other end web,said walls and webs being of cementitious material and providing aunitary structure, each web having a notch extending downwardly from theupper edge to a point intermediate the height of said web and a pair ofseparate generally rectangular blocks of insulating rigid foam material,each insulating block having two spaced parallel notches extendingupwardly from the lower edge, the height of said last named notchesbeing less than the height of said webs below thetnotches therein andspaced downwardly extending notches in the upper edge of said insulatingblock in alignment with said upwardly extending notches, one of saidinsulating blocks being received between said one sidewall and saidintermediate wall with one upwardly extending notch receiving the lowerportion of said intermediate web and the other upwardly extending notchreceiving the lower portion of one end web, the other insulating blockbeing received between said other sidewall and said intermediate wallwith the upwardly extending notches receiving the lower portions of saidpair of webs, the lower edges of said insulating blocks being spacedabove the lower edges of said walls and the uppertedges projecting abovethe upper edges of said walls with the lower surfaces of said downwardlyextending notches being spaced above the upper edges of said walls bythe width of a mortar joint to provide a composite building block withinsulation provided by said insulating blocks.

4. An insulated building wall having uniform mortar joints, said wallcomprising a plurality of composite insulated building blocks laid in abroken joint pattern with mortar joints therebetween, each buildingblock comprising spaced parallel rectangular sidewalls and anintermediate wall, vertical end webs and an intermediate web connectingone sidewall and said intermediate wall, the thickness of each end webbeing approximately one-half the thickness of said intermediate web, apair of spaced vertical webs connecting the other sidewall and saidintermediate wall, one of said pair being disposed in a plane betweensaid intermediate web and one end web and the other of said'pair beingdisposed in a plane between said intermediate web and the other end web,said walls and webs being of cementitious material and providing aunitary structure, each web having a notch extending downwardly from theupper edge to a point intermediate the height of said web, the outerside edges of the notches in said end and intermediate webs being spacedinwardly from the inner surface of said one sidewall, the outer sideedges of the notches in said pair of webs being spaced inwardly from theinner surface of said other sidewall and a pair of separate generallyrectangular blocks of insulating rigidfoam material, each insulatingblock having two spaced parallel notches extending upwardly from thelower edge, the height of said last named notches being less than theheight of said webs below the notches therein and spaced downwardlyextending notches in the upper edge of said insulating block inalignment with said upwardly extending notches, one of said insulatingblocks being received between said one sidewall and said intermediatewall with one upwardly extending notch receiving the lower portion ofsaid intermediate web and the other upwardly extending notch receivingthe lower portion of one end web, the other insulating block beingreceived between said other sidewall and said intermediate wall with theupwardly extending notches receiving the lower portions of said pair ofwebs, the lower edges of said insulating blocks being spaced above thelower edges of said walls and the upper edges projecting above the upperedges of said walls with the lower surfaces of said downwardly extendingnotches being spaced above the upper edges of said walls by the width ofa mortar joint to provide a composite building block with insulationprovided by said insulating blocks and by the air spaces between theouter sides of said insulating bloclrs and the inner surfaces of saidsidewalls, the upwardly extending notch in said one insulating blockreceiving the lower portion of one end web also receiving the lowerportion of the end web on the adjacent building block, the ends of saidother insulating block engaging the ends of the corresponding insulatingblocks in adjacent building blocks to provide uniform vertical mortarjoints therebetween and the lower edges of the webs on the adjacentcourse of building blocks being received in the downwardly extendingnotches in said insulating blocks to accurately locate the buildingblocks in said adjacent courses and provide uniform horizontal mortarjoints.

5. An insulated building wall having uniform mortar joints, said wallcomprising a plurality of composite insulated building blocks layed in abroken joint pattern with mortar joints therebetween, each buildingblock comprising spaced parallel rectangular sidewalls and anintermediate wall, vertical end webs and an intermediate web connectingone sidewall and said intermediate wall, the thickness of each end webbeing approximately one-half the thickness of said intermediate web, apair of spaced vertical webs connecting the other sidewall and saidintermediate wall, one of said pair being disposed in a plane betweensaid intermediate web and one end web and the other of said pair beingdisposed in a plane between said intermediate web and the other end web,said walls and Webs being of cementitious material and providing aunitary structure, each web having a notch extending downwardly from theupper edge to a point intermediate the height of said web and a pair ofseparate generally rectangular blocks of insulating rigid foam material,each insulating block having two spaced parallel notches extendingupwardly from the lower edge, the height of said last named notchesbeing less than the height of said webs below the notches therein andspaced downwardly extending notches in the upper edge of said insulatingblock in alignment with said upwardly extending notches, one of saidinsulating blocks being received between said one sidewall and saidintermediate wall with one upwardly extending notch receiving the lowerportion of said intermediate web and the other upwardly extending notchreceiving the lower portion of one end web, the other insulating blockbeing received between said other sidewall and said intermediate wallWith the upwardly extending notches receiving the lower portions of saidpair of webs, the lower edges of said insulating blocks being spacedabove the lower edges of said walls and the upper edges projecting abovethe upper edges of said walls with the lower surfaces of said downwardlyextending notches being spaced above the upper edges of said walls bythe width of a mortar joint to provide a composite building block withinsulation provided by said insulating blocks, the upwardly extendingnotch in said one insulating block receiving the lower portion of oneend web also receiving the lower portion of the end Web on the adjacentbuilding block, the ends of said other insulating block engaging theends of the corresponding insulating blocks in adjacent building blocksto provide uniform vertical mortar joints therebetween and the loweredges of the webs on the adjacent courses of building blocks beingreceived in the downwardly extending notches in said insulating blocksto accurately locate the building blocks in said adjacent courses andprovide uniform horizontal mortar joints.

6. A composite insulated building block comprising spaced parallelrectangular sidewalls, spaced parallel vertical webs connecting saidsidewalls, said sidewalls and webs being of cementitious material andproviding a unitary structure, each web having a notch extending fromthe upper edge downwardly to a point intermediate the height of saidweb, the side edges of said notches being spaced inwardly from the innersurfaces of said sidewalls and a separate generally rectangular block ofinsulating rigid foam material, said insulating block having spacedparallel notches extending upwardly from the lower edge to a pointintermediate the height, one side of said insulating block being offsetlongitudinally and vertically with respect to the opposite side toprovide an upstanding rib on one side of the upper edge surface, adepending rib on the opposite side of the lower edge surface, a flangeprojecting from one end in alignment with said upstanding rib and asecond flange projecting from the opposite end in alignment with saiddepending rib, said upstanding rib having spaced parallel notchesextending downwardly in alignment with said upwardly extending notchesand terminating at the upper edge of said insulating block, saidinsulating block being received between said sidewalls in the notches insaid webs and with the lower portions of said webs received in theupwardly extending notches in said insulating block, the lower edge ofsaid depending rib being flush with the adjacent lower edges of saidsidewalls, the end of said flange on said opposite end being flush withthe adjacent end edges of said sidewalls, the upper edge of saidinsulating block projecting above the upper edges of said sidewalls bythe width of a mortar joint and said one end projecting beyond theadjacent end edges of said sidewalls by the width of a mortar joint toprovide a composite building block with insulation provided by saidinsulating block and by the air spaces between the sides of saidinsulating block and the inner surfaces of said sidewalls.

7. A two-part composite insulated building block, one part comprisingspaced parallel rectangular sidewalls, spaced parallel vertical websconnecting said sidewalls, said sidewalls and webs being of cementitiousmaterial and providing a unitary structure, each web having a notchextending from the upper edge downwardly to a point intermediate theheight of said web and a second part comprising a separate generallyrectangular block of insulating rigid foam material, said insulatingblock having vertically extending parrallel outer surfaces, saidsurfaces being spaced from the interior surfaces of said spaced parallelrectangular sidewalls to provide continuous air spaces on both sides ofsaid insulating block, whereby when any moisture penetrates thecementitious block, it will collect on outer surfaces of said insulatingblock and will be evaporated due to the air currents in said air spaces,said insulating block having spaced parallel notches extending upwardlyfrom the lower edge to a point intermediate the height, one side of saidinsulating block being offset longitudinally and vertically with respectto the opposite side to provide an upstanding rib on one side of theupper edge surface, a depending rib on the opposite side of the loweredge surface, a flange projecting from one end in alignment with saidupstanding rib and a second flange projecting from the opposite end inalignment with said depending rib, said upstanding rib having spacedparallel notches extending downwardly in alignment with said upwardlyextending notches and terminating at the upper edge of said insulatingblock, said insulating block being received between said sidewalls inthe notches in said webs and with the lower portions of said websreceived in the upwardly extending notches in said insulating block, thelower edge of said depending rib being flush with the adjacent loweredges of said sidewalls, the end of said flange on said opposite endbeing flush with the adjacent end edges of said sidewalls, the upperedge of said insulating block projecting above the upper edges of saidsidewalls by the width of a mortar joint and said one end projectingbeyond the adjacent end edges of said sidewalls by the width of a mortarjoint to provide a composite building block with insulation provided bysaid insulated block.

8. An insulated building wall having uniform mortar joints, said wallcomprising a plurality of two-part composite insulated building blockslayed in a broken joint pattern with mortar joints therebetween, onepart of each building block comprising spaced parallel rectangularsidewalls, spaced parallel vertical webs connecting said sidewalls, saidsidewalls and webs being of cementitious ,material and providing aunitary structure, each web having a notch extending from the upper edgedownwardly to a point intermediate the height of said web, the sideedges of said notches being spaced inwardly from the inner surfaces ofsaid side walls and a second part comprising a separate generallyrectangular block of insulating rigid foam material, said insulatingblock having vertically extendingparallel outer surfaces, said surfacesbeing spaced from the interior surfaces of said spaced parallelrectangular side walls to provide continuous air spaces on both sides ofsaid insulating block, whereby when any'moisture penetrates thecementitious block, it will collect on outer surfaces of said insulatingblock and will be evaporated due to the air currents in said air spaces,said insulating block having spaced parallel notches extending upwardlyfrom the lower edge to a point intermediate the height, one side ofsaidinsulating I blockbeing offset longitudinally and vertically withrespect to the opposite side to provide an upstanding rib on one side ofthe upper edge surface, a depending rib on the opposite side of thelower edge surface, a flange projecting from one end in alignment withsaid upstanding rib and a second flange projecting from the opposite endin alignment with said depending rib, said upstanding rib having spacedparallel notches extending downwardly in alignment with said upwardlyextending notches and terminating at the upper edge of said insulatingblock, said insulating block being received between said sidewalls inthe notches in said webs and with the lower portions of said websreceived in the upwardly extending notches in said insulating block, thelower edge of said depending rib being flush with the adjacent loweredges of said sidewalls, the end of said flange on said opposite endbeing flush with the adjacent end edges of said sidewalls, the upperedge of said insulating block projecting above the upper edges of saidsidewalls by the width of a mortar joint and said one end projectingbeyond the adjacent edges of said sidewalls by the width of a mortarjoint to provide a composite building block with insulation provided bysaid insulating block and by the air spaces between the sides of saidinsulating block and the inner surfaces of said sidewalls, said one endof said insulating block engaging the end of the flange on said oppositeend of the adjacent insulating block to provide uniform vertical mortarjoints, the lower edges of the webs in succeeding courses being receivedin the notches in said upstanding rib to locate the webs in succeedingcourses in vertical alignment and the upper edge of said insulatingblock engaging the lower edges of the webs in the next succeeding courseto provide a uniform horizontal mortar joints.

9. An insulated building wall having uniform mortar joints, said wallcomprising a plurality of two-part composite insulated building blockslayed in a broken joint pattern With mortar joints therebetween, onepart of each building block comprising spaced parallel rectangularsidewalls, spaced parallelvertical webs connecting said sidewalls, saidsidewalls and webs being of cementitious material providing a unitarystructure, each web having a notch extending from the upper edgedownwardly to a point intermediate the height of said web and the secondpart comprising a separate generally rectangular block of insulatingrigid foam material, said insulating block having vertically extendingparallel outer surfaces,

said surfaces being spaced from the interior surfaces of said spacedparallel rectangular side walls to provide continuous air spaces on bothsides of said insulating block,'whereby when any moisture penetrates thecementitious block, it will collect on outer surfaces of said insulatingblock and will be evaporated due to the air currents in said spaces,said insulating block having spaced parallel notches extending upwardlyfrom the lower edge to a point intermediate the height, one side of saidinsulating block being offset longitudinally and vertically with respectto the opposite side to provide an upstanding rib on one sideof theupper edge surface, a depending ribon the opposite side of the loweredge surface, a flange projecting from one end in alignment with saidupstanding rib and a second flange projecting from the opposite end inalignment with said depending rib, said upstanding rib having spacedparallel notches extending downwardly in alignment with said upwardlyextending notches and terminating at the upper edge of said insulatingblock, said insulating block being received between said sidewalls inthe notches in said webs and with the lower portions of said websreceived in the upwardly extending notches in said insulating block, thelower edge of said depending rib being flush with the adjacent loweredges of said sidewalls, the end of said flange on said opposite endbeing flush with the adjacent end edges of said sidewalls, the upperedge of said insulating block projecting above the upper edgesof saidsidewalls by the width of a mortar joint and said one end projectingbeyond the adjacent end edges of said sidewalls by the width of a mortarjoint to provide a composite building block with insulation provided bysaid insulating block, said one end of said insulating block engagingthe end of the flange on said opposite end of the adjacent insulatingblock to provide uniform vertical mortar joints, the lower edges of thewebs in succeeding courses being received in the notches in saidupstanding rib to locate the webs in succeeding courses in verticalalignment and the upper edge of said insulating block engaging the loweredges'of said webs in the next succeeding course to provide uniformhorizontal mortar joints.

References Cited by the Examiner UNITED STATES PATENTS 960,562 6/ 10Lanning 52-607 1,171,913 2/16 Wilson 52-405 1,621,957 3/27 Schweizer52412 2,199,112 4/40 OLeary 52405 FOREIGN PATENTS 931,227 9/47 France.

1,032,337 3/53 France.

1,140,694 3 5 7 France.

429,803 6/35 Great Britain. 287,492 4/ 5 3 Switzerland.

OTHER REFERENCES The Architectural Forum, May 1944, page 166.

RICHARD W. COOKE, JR., Primary Examiner.

HENRY C. SUTHERLAND, Examiner.

1. A COMPOSITE INSULATED BUILDING BLOCK COMPRISING SPACED PARALLEL RECTANGULAR SIDEWALLS AND AN INTERMEDIATE WALL, VERTICAL END WEBS AND AN INTERMEDIATE WEB CONNECTING ONE SIDEWALL AND SAID INTERMEDIATE WALL, THE THICKNESS OF EACH END WEB BEING APPROXIMATELY ONE-HALF THE THICKNESS OF SAID INTERMEDIATE WEB, A PAIR OF SPACED VERTICAL WEBS CONNECTING THE OTHER SIDEWALL AND SAID INTERMEDIATE WALL, ONE OF SAID PAIR BEING DISPOSED IN A PLANE BETWEEN SAID INTERMEDIATE WEB AND ONE END WEB AND THE OTHER OF SAID PAIR BEING DISPOSED IN A PLANE BETWEEN SAID INTERMEDIATE WEB AND THE OTHER END WEB, SAID WALLS AND WEBS BEING OF CEMENTITIOUS MATERIAL AND PROVIDING A UNITARY STRUCTURE, EACH WEB HAVING A NOTCH EXTENDING DOWNWARDLY FROM THE UPPER EDGE TO A POINT INTERMEDIATE THE HEIGHT OF SAID WEB, THE OUTER SIDE EDGES OF THE NOTCHES IN SAID END AND INTERMEDIATE WEBS BEING SPACED INWARDLY FROM THE INNER SURFACE OF SAID ONE SIDEWALL, THE OUTER SIDE EDGES OF THE NOTCHES IN SAID PAIR OF WEBS BEING SPACED INWARDLY FROM THE INNER SURFACE OF SAID OTHER SIDEWALL AND A PAIR OF SEPARATE GENERALLY RECTANGULAR BLOCKS OF INSULATING RIGID FOAM MATERIAL, EACH INSULATING BLOCK HAVING TWO SPACED PARALLEL NOTCHES EXTENDING UPWARDLY FROM THE LOWER EDGE, THE HEIGHT OF SAID LAST NAMED NOTCHES BEING LESS THAN THE HEIGHT OF SAID WEBS BELOW THE NOTCHES THEREIN AND SPACED DOWNWARDLY EXTENDING NOTCHES IN THE UPPER EDGE OF SAID INSULATING BLOCK IN ALIGNMENT WITH SAID UPWARDLY EXTENDING NOTCHES, ONE OF SAID INSULATING BLOCKS BEING RECEIVED BETWEEN SAID ONE SIDEWALL AND SAID INTERMEDIATE WALL WITH ONE UPWARDLY EXTENDING NOTCH RECEIVING THE LOWER PORTION OF SAID INTERMEDIATE WEB AND THE OTHER UPWARDLY EXTENDING NOTCH RECEIVING THE LOWER PORTION OF ONE END WEB, THE OTHER INSULATING BLOCK BEING RECEIVED BETWEEN SAID OTHER SIDEWALL AND SAID INTERMEDIATE WALL WITH THE UPWARDLY EXTENDING NOTCHES RECEIVING THE LOWER PORTIONS OF SAID PAIR OF WEBS, THE LOWER EDGES OF SAID INSULATING BLOCKS BEING SPACED ABOVE THE LOWR EDGES OF SAID WALLS AND THE UPPER EDGES PROJECTING ABOVE THE UPPER EDGES OF SAID WALLS BY THE WIDTH OF A MORTAR JOINT DOWNWARDLY EXTENDING NOTCHES BEING SPACED ABOVE THE UPPER EDGES OF SAID WALLS BY THE WIDTH OF A MORTAR JOINT TO PROVIDE A COMPOSITE BUILDING BLOCK WITH INSULATION PROVIDED BY SAID INSULATING BLOCKS AND THE AIR SPACES BETWEEN THE OUTER SIDES OF SAID INSULATING BLOCKS AND THE INNER SURFACES OF SAID SIDEWALLS. 